Manufacture of ingot iron and steel



u e nv h s nu e .n s 2 E T R O W S N I A H W d. d o M 0 /N\ MANUFAoURE0F INGOT IRON AND. STEEL. 774

Patented July 5, 1881.

(No Model.) Sheets-Sheet 2.

W. HAINSWORTH.

MANUPAGTURE 0F INGOT IRON AND STEEL. I No. 243,774. y Patented July5,1881.

N. meng Mvumogmn w 5m n. c.

UNITED STATES PATENT OFFICE.

WILLIAM HAINSVVORTH, OF PITTSBURG, PENNSYLVANIA.

MANUFACTPURE OF lNGOT IRON AND STEIEL.A

SPECIFICATION forming part of Letters Patent No. 243,774, dated July 5,1881.

Application filed January 10, 1881.

Pennsylvania, have invented or discovered a` new and useful Improvementin Manufacture of Ingot Iron and Steel; and I do hereby declare thefollowing to be a full, clear, concise,

'and exact description thereof', reference being had to the accompanyingdrawings, making a part of this specification, in which-like lettersindicating like parts- Figure 1, Sheet 1, is a plan view, showing themain appliances required in carrying out my present invention. Fig. 2,Sheet 2, is a sectional elevation in the plane of the line x a: of Fig.1,but with the upper end of slidingbox case sectionedin the line 002,Fig. l. Fig. 3 is a sectional view in the plane of the line fr x of Fig.2. Fig. 4 is a perspective view of the movable Hue box or case, showingthe flue-port openings which come opposite the converter-mouth; and Fig.5 is a detached side view of the pouring end of the converter,

Bessemer Vand Siemens-'Martin or open-hearth processes, with referenceto securing from 'the Bessemer or a similar converter the variableproducts or qualities of product heretofore obtained from the openhearth.

In carrying out this part of my invention I employ the ordinary or anysuitable form of Bessemer converter, provided with an airblast, means ofrotation, and other appliances such as are usual or necessary, and inthe usual way of working the air-blast or Bessemer process I bring thecharge to such stage or degree of purification as, being attainable bythat process, may be desired, and ordinarily7 I prefer to continue theblowing until all, or nearly all, the carbon is eliminated. Heretoforeit has been usual, after this stage of treatment has been reached, torotate the converter to a horizontal, or nearly horizontal, position andrecarbonize the molten charge till it possesses the desired percentageof carbon, or till (No model.)

its quality or constituent elements were otherwise changed by theintroduction of spiegel,

ferro-manganese, or other metals or metallic variety, as well as greaterpurity, of product,`

and this is largely due to the fact that the metal can be keptin amolten state as long as may be necessary without any such destructive.or wasteful 4action thereonof the heat employed as in the Bessemerprocess would result from a continuance of the blowing opertion. Thisfacility possessed by the openhearthl process ofkeepingthe metal in amolten condition indefinitely without deleterious results and withpositive benet gives to this process a decided advantage over theBessemer, since it enables the manufacturer to charge and recharge asoften as he may desire into the molten metal such other metal ormetallic alloy or mixture of the same as he may wish with reference togetting such quality of product as he may desire, or one quality ofproduct from or after one or more such charging operations and anotherquality from or after one or more such other' charging operations, sothat from the original charge of metal in the converter two or moredifferent qualities of product may be obtained. Also, by treatingBessemer metal or product by the open-hearth process I secure resultswhich are practically unattainable by the Bessemer process alone in theelimination of phosphorus and the oxidation of silicon. Phosphorus isoxidized with rapidity at a lower temperature than can be got in theblowing operation; but by a prolonged exposure in the open-hearthprocess after the blowing ceases it may be largely oxidized, so as to gointo the slag. And another advantage appertainingvto the open-hearthprocess, and also arising from the ability to keep the charge in a fluidstate for a considerable time,is that the manufacturer can Work into thecharge a largel percentage of scrap, so as to utilize the same, and, sofar as I am aware, this is the cheapest and best IOO process known forconverting scrap into merchant iron or steel; and, furthermore, thecombination of the two processes enables me to use a commoner kind ofcast-iron, with perhaps a large percentage of vphosphorus, than hasheretofore been practicable with the airblast process alone, and stillget an equally good product as in the basic process and at a much lessexpense.

Now, by my present invention, after I have worked the Bessemer processas above stated, I rotate the converter to a horizontal, or nearlyhorizontal7 position, so that the level of the metal in the convertershall be below the level of the tuyere-openings, and having shut offlthe air-blast, I apply to the metal a flame or lheat such as isemployed in the open-hearth process, and while the metal is thereby keptin a iiuid condition, and also further purified, I introduce iron andsteel scrap, spiegel, ferromanganese, cast-iron, or other metal ormetallic alloy, or mixture of the same, substantially as practiced inthe open-hearth-process, with reference either to increasing thequantity of the molten metal or to varying its quality, or both.

If I nd by testing that I have added toov much of one or more metals oralloys, I neutralize the same, or so much of them as may be desirable,by adding the proper ingredient or .ingredients for the purpose; or if Idesire one quality7 or product for one purpose and another quality foranother purpose, and desire to take both from the same charge, I iirst,by adding the proper metal or alloy or mixture, bring the charge to oneof the desired qualities, pour off whatever may be required, then by theuse of some other metal or alloy or mixture bring the charge to theother of the desired qualities, or make other desired variations intreatment, all as practiced in connection with the open-hearth process,and during all this time, except while the pouring is being done, Iprovide for keeping up the action of the heat or dame on the surface ofthe metal, so as to preserve irs fluidity and perfect its quality whilethe treatment referred to is in progress.

In working this combined air-blast or Bessemer and open-hearth process Imake use of apparatus some of which is old and some of which I believeto be new.

B represents a converter of the ordinary Bessemer form and construction,and which, with its attachments and co-operative appliances-such astuyere-box z, blast-pipe z', tiltingmechanism z2, and its manner ofworkingare so well known that they need not be further described. Insuch or a similar converter I treat the metal by the air-blast in theusual way till it is free, or practically free, of carbon, or arrestingthe process sooner, if so desired. I then rotate the converter to aposition hori- Zontal, or nearly so, so as to bring the level of themolten metal below the tuyere-openings, cut oif the blast, and introduceinto the converter-mouth what is sometimes called an oxidining heat oriiame.77

The apparatus employed in this part of the operation I will nextdescribe.

P represents a top view of a gas-producer of any suitable construction,and which may be arranged at any convenient point out of the way ofother operations which have to be carried on with rapidity. As shown, itis outside the pit p, in which the pouring or casting is to be done. Theiiue a' goes over and down into an underground flue, a. (Shown by dottedlines in Fig. l and partly by dotted and partly by full lines in Fig.3.) This fine opens at a2, Fig. 2, into a chamber, a3, built in themasonry or abutment A. Directly opposite this abutment A, and at alittle distance therefrom, I build a like abutment, A', and make thereina chamber, a, Fig. 3, which leads down and opens into a iiue, a5, Fig.2, which latter is carried back alongside of the iiue. a to the stack P.

The abutments A A are inclined, as represented in Fig. 2, and theirinner faces are made with a slight incline or bevel, as illustrated bythe lines s sin Fig. 3. Also, the flue-chambers a3 a4 are`open on theirinner or adjacent sides, so that a3 shall open into a flue, c, whichopens directly into the convertermouth when the latter is rotated to ahorizontal position, and another line, c', leading from theconverter-mouth, opens at its other end'into the other flue-chamber, a4.

The tlues c c are made in a box or case, C, which is made movable, sothat when the pouring is to be done no obstruction shall be in the way.It may be moved into and out of position in front of the converter-mouthin anyT suitable way-as, for example, it may be raised and lowered by acrane from above; but I believe it better 1o arrange it on an incline,b, in a suitable pit, b', and slide it up and down on suitable guides orways, b2. Its lower end is made of a wedge shape, such that it will fitneatly in bet'ween the abutments A A and bring the communicating portsinto line, as clearly illustrated in Fig. 3. As a device for moving itinto and out of position with its upper end opposite theconverter-mouth, I prefer to use a hydraulic cylinder, D, thepiston-stem d of which is connected directly to the box C.

Pipe and ports for supplying and exhausting water-pressure arerepresented at d; but other forms or constructions of hydraulic orfluid-pressure apparatus may be substituted for that shown. As soon asthe converter is turned down, as above stated, the box or case C is runup to position, as shown.

The gas from producer I? passes by fines a a, chamber a3, and line cinto the converter, where it is ignited in connection with an air jet orsupply, introduced as presently to be described. The flame and heat passaround the inside of the converter, on or just above the level orsurface of the molten metal therein, in a kind of a swivel, and performsubstantially the same function as in the open-hearth IOS IIO

furnace, and, more particularly, keep up and preserve the fluidity ofthe metal without damage or material waste, and perhaps cooperate inimproving its quality. Waste heat 5 and gases pass out by the flue c',chamber a4,

and tlue a5 to the stack; but in doing so they impart a considera-blepercentage ot' their heat to the walls of the tlues a c, andparticularly to the partition-walls, so that the ingoing gases 1opassing through a and c shall, hy taking up heat therefrom, be raised tothe desired high temperature before reaching the point of igni- 'tionand combustion.

In this manner I apply the principle ofthe 1 5 regenerator-furnace tothe heating of the gases employed in the converter; and while I preferthis mode of using the regenerator principle simply because it is acheap, easy, and convenient way of utilizing the waste heat of the zeconverter for the purpose specified, I do not in this part of myinvention limit myself thereto, but includeas the equivalent thereof anysuitable form of regenerator apparatus arranged in the lne ofcommunication between z 5 the gas-producer and the converter, wherebythe ingoing gases shall be artificially raised in temperature above whatthey possess on leaving the producer.

l will next describe the apparatus for heat- 3o ing and introducing theheated air.

In an application already tiled I have shown and claimed a pipe forcarrying off the waste products of the Bessemer blowing operation,

as the-same pass off or are blown oft' while' the blowing is inprogress.

This pipe I showed as having (when in position) its open end directlyover the converter-month, the latter being vertical or in a blowingposition. Such pipe then passes over in a goose-neck form to aoapointout of the way, thence beneath the surface of the ground, and oft' toany desired point where the waste heat and gases could be utilized; butsuch utilization was not claimed there, nor is it claimed here, exceptas it is -used for heating a column or flow of air, which 5o the tiltingmotion ofthe converter.

A matter of a separate application.

At suitable points-say at thejunctions of sections B with B2 and of B2with BS-I arrange a damper device, such that the pipes may be closed oropened at pleasure. Dampers suita- 6o ble for the purpose are common,and hence I have merely shown damper-cases n n in which to operate theordinary form of sliding damper, the handles of which are represented atu2. These dampers being open and the swing-section B' being over theconverter-mouth while the blowing, is in progress, waste heat, gases,

sparks, &c., will be conducted oft' and discharged; but after theblowing operation is finished and the converter is tilted preparatory tothe further treatment of the metal, as described, I close both dampers.

To the section B2, at or near the end farthest from the converter, isconnected an air-pipe, c, .which leads from any suitable blowingapparatus or device, by the use ot' which a blast ot' air can be driveninto or along the heated pipesection B2. From a point at or near theother end o f said section B2, I take a pipe, c', over and lead it intothe gas-flue c at or near the point where the latter opens into theconvertermouth, as illust-rated in Fig. 2, so that a blast or jet ot'heated air will be supplied to the gas at or about the proper point forthe intermixture of the two preliminary to their ignition andcombustion, and so as to secure the proper action of the heat or flameso generated in the converter, as already described. The outgoing wasteheat and gas given o' in the blowing opera-tion will have heated thesection B2 to a high temperature, so that the air, on being driven orforced through it, will be raised to the proper temperature lfor doingits work. Also, the blowing action should be sufficient in amount ordegree so that the escaping air shall create and keep up the properdraft in the ilues a c, so as to bring the gas forward from theproducer.

It will thus be seen that I also employ the regenerator principle in theheating of the air, using for that purpose the waste heat of the blowingoperation; but in this case also, as in the case of the gas, while Ibelieve this to bel the easiest, cheapest, and simplest way ot' doingthe work described, I do not limit myself thereto, but include hereinlike modifications and substitutes as in the heating of the gas.

The metal and alloys used or usable in the open-hearth process forincreasing the quantit-y ofthe charge, as well as for varying itsquality, are so many and various, but at the same time so well known,that I do not deem it necessary to describe them.

In my present invention I use or propose to use any or all of them,andin like manner, but under the conditions herein prescribed,forthepurpose of increasing thequantity or varying the quality of a blownBessemer charge while still retained in the converter, as the same havebeen used or are usable on,in, or in connection with a charge of metalon the open hearth; and the described process has the very greatadvantage .of combining the quickness and cheapness ofthe Bessemerprocess with the variable capacity and accuracy of result whichappertain to the open-hearth process. This process also providesconditions for the partial elimination from Bessemer lnetal or productof phosphorus, and for the more complete oxidation of silicon, onaccount of the long exposure ot' the bath to oxygen and of the sepa-Vration of the oxides so formed from the metal,

the same going into the slag. Also, grades or IOO IIC

qualities of metal which heretofore could not be worked by theBessem eror air-blast process may by this process be made to give aproductequally as good as by the open-hearth process alone or by thebasicprocess.

Since the box C covers the converter-mouth while such subsequenttreatment is in progress, I provide in the side or wall ofthe converter,preferably at or near its mouth, a door, fi, of suitable size for theintroduction of such metals, alloys, or chemicals as may be desired, andthis door, preferably of conical or pyramidal forin, may be opened andclosed, and when closed be fastened by any suitable devices, such as areknown in the art for such purposes, as by a hinge, t', and pivotedlockin g-bar, t2, engaging suitable catches, t3, Fig. 5.

For turning` on and shutting off the flow of gas and air, any suitablearrangement of cock, valves, dam'pers, or gates may be added.

I do not deem it absolutely necessary to the working of the describedprocess that the waste gases leave the converter by its mouth, as itwould be practicable to remove the tuyerebox after each blowing and makethe wastetlue connection at that end of the converter.

The process thus described is valuable, not only for making variousgrades or qualities of ingot iron or of steel in ingot form, but also itis of value in the preparation of metals or materials to be run oft'directly to the molds for the making of all sorts of cast ingot-iron orcaststeel castings, and such, among other uses, I include herein.

The making of cast-steel castings is already a well-known branch of theart, and this invention is designed, ir. part, as a more effect.- ive,cheaper, and more certain method of and apparatus for preparing materialfrom castiron for the making of such castings.

I am aware that, broadly speaking, it is not new, after treating acharge of metalin a converter by the Bessemer process, to rotate 'theconverter to a horizontal' position and inject gas through a tuyereabove the surface ofthe charge; and also that it is not new to employthe outgoing waste heat of an ordinary fixed furnace-chamber to heat thein going gases, and hence I make no claim to such features ofconstruction by themselves considered.

I am also aware that a rocking basin-shaped con Vertin g-chamber orhearth havin glateral or end heat-supply and waste-ports has beencombined with an arrangement of gas and air dues for treating the metalwith air and gas, injected sometimes beneath and sometimes above thesurface of the metal; but I am not aware of any prior combination with aBesse mer converter of gas and air flues such that, after the metal hasbeen treated to the desired extent by the air-blast while in an uprightor vertical position, and the converter has been turned down to ahorizontal position, or one substantially horizontal, a combined streamof air and gas can be turned onto the metal through the open mouth ofthe converter, with provision for carrying oi' the waste gases throughthe converter-mouth, and such combination is included herein, whetherthe fluebox be movable or stationary.

I claim herein as my inventionl. In combination with an air-blastconverter, a movable tine-box, C, having gas and air conduits or portsopening unitedlyinto the converter-mouth, and a gas-escape conduit,suhstantially as set forth.

2. rIhe combination of an air-blast converter, a gas producer andregenerator, au airblast and air-regenerator, and a movable fluebox C,which, when in position for work, brings the gas, air, and waste uesunitedly at the converters mouth, substantially as set forth.

3. The abutments A A', arranged and chambered as described, incombination with movable flue-box C and piston and cylinder for movingthe same, substantially as set forth.

4. In combination with an air-blast converter, a movable due-box, C, anda cylinder and piston for moving the same into and out of positionrelative to the converters mouth when in a tiltedposition, substantiallyas set forth.

and to carry off the waste gas, heat, Svc., also,

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